HACCP and Food Recall Essentials for

School Nutrition Professionals

Cindy Rice, RS, MSPH

October 19, 2016

Nuts and Bolts Workshop DESE

Framingham State College

Insects flying

Falling dirt

Food mixed with bare hand, cuts

Foods in TDZ for 5 hours

Worker did not wash hands after restroom and then put fruit in

bowl

Food Safety Essentials

Learning objectives

• Understand the main hazards to food

• Identify TCS foods and their characteristics

• Know the major allergens and control measures

Major Risks to Food

Biological

Chemical

Physical

• Foodborne Illness

A disease that is carried or transmitted

to people by food

• Outbreak

An incident in which 2 or more people experience

the same illness after eating the same food

Foodborne Illness

High Risk Populations

People with weakened immune systems

Babies & Children under 4

Elder Adults Chronic disease or ill individuals

High risk individuals

AVOID:

Raw Sprouts

Soft cheeses

Cold cuts/Deli Meats

Rare meats

Raw seafood

(Use Pasteurized eggs)

TCS Time and Temperature Control for Safety foods

(formerly Potentially Hazardous Foods)

Bacteria will grow easily:

• High in protein or carbohydrates

• Moist

• Neutral or only slightly acidic

TCS foods

TCS foods

Which type of food would be the most likely to cause a foodborne illness? A. Tomato juice B. Cooked rice C. Whole wheat flour D. Dry powdered milk

Pop Quiz

All of the following conditions typically support the growth of microorganisms EXCEPT: A. moisture B. a protein or carbohydrate food source C. high acidity D. time

Pop Quiz

Flow of Food

3 Main Hazards to Food

• Poor Personal Hygiene

• Cross-Contamination

• Time-Temperature Abuse

Personal Hygiene

• Wash hands properly

• Stay clean

• Don’t work while sick

• Don’t eat, drink or smoke around food

Time and Temperature Abuse

Major cause of foodborne illness outbreaks

Bacteria grow to dangerous levels

in TDZ (Temperature Danger Zone) 41° F – 140° F 2 hour maximum for Schools Discard

140 ° F

41° F

Time and Temperature Controls

Minimize time at 41° F – 140° F

Keep TCS foods under 2 hours total

Receive & store TCS foods quickly

Refrigerate TCS foods at proper temperatures, 41° F or lower

Cook foods to safe internal temperatures

Hold foods at proper temperatures

Cool, thaw, reheat foods properly

Cross-Contamination

• Wash hands after handling raw foods

• Don’t allow raw foods to touch or drip onto cooked or ready-to-eat foods

• Clean and sanitize food contact surfaces, cloths

Food Allergies

• Eggs • Dairy • Wheat • Soy (tofu) • Tree nuts • Peanuts • Fish • Shellfish Protein in the food is what causes the allergic reaction Gluten, Lactose Intolerances- sensitivities

Food Allergens – The Big 8

Preventing Allergic Reactions

Prevent cross-contact

• Avoid use of offending ingredients

• Know ingredients, read labels

• Use clean equipment, gloves

• Separate fryers

and cooking oils

Use Clean Equipment

Wash, rinse (and sanitize) all surfaces

• pots, dishes

• utensils, tables

• cutting boards

• wiping cloths

Foodborne microorganisms grow well at temperatures between A. 75° F and 165° F B. 32° F and 79° F C. 38° F and 155° F D. 41° F and 135° F .

Pop Quiz

Which of the following is not a common food allergen? A. Tofu B. Dairy products C. Peanuts D. Strawberries

Pop Quiz

HACCP Food Safety Systems

HACCP

• Hazard Analysis Critical Control Point

• A written plan, an organized way of how foods

are prepared in an operation

Learning objectives

• Identify the 7 HACCP principles

• Know the methods for identifying hazards in foods in a HACCP plan

• Identify Critical Control Points, monitoring and recordkeeping procedures

Flow of Food

Why HACCP?

Purpose:

Identify possible hazards in the

flow of food ahead of time

Why HACCP?

So we can...

• Prevent hazards

• Eliminate hazards

• Reduce risks to safe levels

Hazards = anything that may cause illness

7 HACCP Principles

Principle One Conduct a Hazard Analysis

Principle Two Determine the CCPs

Principle Three Establish Critical Limits

Principle Four Establish Monitoring Procedures

Principle Five Take Corrective Action

Principle Six Verify that the system works

Principle Seven Record keeping

1. Conduct Hazard Analysis

• Identify potentially hazardous foods from your menu

• Determine which are significant and must be addressed in HACCP plan

Roast turkey

• Determine which are significant and must be addressed in HACCP plan

Hazards

Control them at each step

2. Critical Control Points (CCP)

LAST step where it is ESSENTIAL that you

intervene to make that food safe to eat (prevent, control, or eliminate hazards in food before service)

CCP

3. Establish Critical Limits

• “Magic” number that the CCP must meet

eg, pH value, temperature, time limit

• Prevent, eliminate or reduce risk to safe level

HACCP plan recipe

CCP

Receive fresh < 41°F; Inspect quality of package

Refrigerate < 41°F; Store on lower shelf, no contamination

Place into roasting pan, sprinkle with herbs Clean & Sanitize surrounding area

Cook for 3 hours, to internal temp 165°F for 15 secs

4. Monitoring

• Monitoring (taking a measurement) lets you know

if critical limits are being met

• Be specific about

Who- What- When-Where- How you will monitor

• Equipment and tools needed

HACCP plan recipe

CCP

Receive fresh < 41°F; Inspect quality of package

Refrigerate < 41°F; Store on lower shelf, no contamination

Place into roasting pan, sprinkle with herbs Clean & Sanitize surrounding area

Cook to internal temp 165°F Measure thigh and breast with a

sanitized, bimetallic thermometer

Slice turkey, put into clean hotel pan. Hold HOT at 135°F. Serve with clean sanitized tongs.

Empty into smaller containers. Cool in ice bath to 70° F within 2 hrs, Cover, put in refrigerator on top shelf.

5. Take Corrective Action

Predetermined steps to take when food does

not meet a critical limit

(if something goes wrong)

6. Verification

Manager determines if your HACCP system is working

according to the plan, and if:

• CCP’s and critical limits are appropriate

• Corrective actions are adequate

• Employees are following procedures

7. Recordkeeping

Proper records allow you to document you are continuously preparing and serving safe food

7. Recordkeeping

• Temperature logs,/sanitizing logs

• Thermometer calibration checks

• Corrective action charts, receiving temps

Records can protect you.

Standard Operating Procedures

Must be in place

for HACCP plan to

work properly

Personal hygiene Cleaning & sanitizing

Reputable suppliers Proper equipment Staff Procedures

The temperature of a roast is checked to see if it has met its critical limit of 145° F. This is an example of which HACCP principle? A. Verification B. Monitoring C. Record-keeping D. Hazard Analysis

Pop Quiz

The temperature of a pot of beef stew is checked during holding. The stew has not met the critical limit of 140° F, and is discarded according to school policy. This is an example of which HACCP principle? A. Monitoring B. Corrective action C. Hazard analysis D. Verification

Pop Quiz

Which of the following Standard Operating Procedures should be in place before you begin developing your HACCP system? A. Personal hygiene program B. Incentive program C. Workplace accident prevention program D. None of the above .

Pop Quiz

47

PROCESS HACCP

• School Foodservice • USDA guidelines • Restaurants

48

• Know how to characterize menu items into Process Groups

• Understand importance of Standard Operating Procedures in controlling hazards

• Identify Critical Control Points for menu items

Learning objectives

49

Procedures that address basic operational and sanitation conditions in an operations

1. Develop Prerequisite Programs

Prerequisite Programs - Purpose

Protect your products from contamination

Control bacterial growth

Proper procedures

Clean and sanitized equipment

Personal hygiene and health of workers • Approved suppliers, water

51

• Who?

• What?

• When?

Standard Operating Procedures SOPs Written specifically for your school

• Where?

• How?

• Why?

Bacteria

Viruses

Poor personal hygiene

Physical objects

Chemical contamination

52

2. Identify Hazards in foods

Diagram that shows the step-by-step progression or “flow” of food through a food preparation process, in sequential order

53

3. Make a Flow Chart for all foods

Use the recipe and/or preparation procedures to lay out food flow into major operational steps...

54

55

Group menu items into 1 of 3 food preparation processes •Process 1 •Process 2 •Process 3

FLOW CHARTS help to group items that have similar processes

56

Review Food Flow

Process 1 Process 2 Process 3

# Trips through Temperature Danger Zone

57

Review Food Flow and TDZ

Process 1 Process 2 Process 3

140° F

Flow of food

Receiving Store Prepare Hold Serve Examples

Sandwiches w/ RTE Fillings Canned Tuna Canned Chicken Deli Meat

Salads Fresh fruits

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Process 1: Food Preparation with No Cook Step

NO complete trip through Danger Zone

Flow of food

Receive Store Prepare Cook Hold Serve

Examples (all for immediate service)

Hamburgers

Roast turkey

Stir fry dishes

59

Process 2: Preparation for Same Day Service

1 complete trip through Danger Zone

Flow of Food

Receive Store Prepare Cook Cool Reheat Serve

Examples

Hot Catered Meal (prepared ahead)

Soup prepared in advance for next day service

Chicken salad made from scratch

Process 3: Complex Food Preparation

2 or more complete trips through Danger Zone

Fried Chicken Recipe

• The chicken is received frozen and stored in the walk-in cooler until thawed.

• Chicken is rinsed with water, dipped in buttermilk and flour.

61

What’s the Process Group?

• Chicken is deep fried for 15 minutes at 400o F.

• Chicken is placed to metal sheet pan and placed under a heat lamp/steam table until served.

62

Fried Chicken

Chicken is placed with clean tongs, onto plates, and onto students’ trays

63

Fried Chicken

64

FRIED CHICKEN How many times through Danger Zone?

RECEIVE STORE THAWING

COOK HOT HOLD SERVE

Process 2: Preparation for Same Day Service

TUNA SALAD How many steps through Danger Zone?

RECEIVE STORE ASSEMBLE

STORE SERVE

Process 1: Food Preparation with NO Cook Step What are CCP(s)? Critical limits?

CCP

0

Chicken salad (made in-house from scratch) How many steps through Danger Zone?

RECEIVE STORE COOKING

COOLING SERVE

Process 3: Complex Food Preparation

What are CCP(s)? Critical limits? Other way to make it a different Process?

CCP

CCP

PREPARE

67

PROCESS Approach

•Critical control points are identified for Groups of menu items (Process 1, Process 2, Process 3 items) •Critical limits may be different within that Group (Meats and poultry in same Process group but have different cooking temperatures) •Critical limits for different foods are identified in SOP for that Procedure (e.g., Cooking)

Chicken casserole, Taco filling

How many steps through Danger Zone?

RECEIVE STORE COOKING

COOLING REHEATING SERVE

Process 3: Complex Food Preparation

What are CCP(s)? Critical limits? SOP’S ?

CCP CCP

CCP

69

LET’S REVIEW

PROCESS HACCP

Which is the first step in grouping menu items into the correct Process Group?

A. Identify hazards of the ingredients

B. Create a Flow chart for each recipe

C. Identify control measures

PROCESS HACCP

Which Process group involve no Cook step?

Process 1

Process 2

Process 3

PROCESS HACCP

Which Process group travels through the Temperature Danger Zone 2 or more times?

A. Process 1

B. Process 2

C. Process 3

PROCESS HACCP

Every Critical Control Point requires a

A. Certified HACCP Manager supervision

B. Validated cooking temperature

C. Monitoring and Recordkeeping activity

Update and re-Validate plan with every change in process, ingredient, menu item

HACCP System Success

To protect our children!

Responding to Food Recalls

.

Kiwis ...Italy

Hazelnuts ...Asia

Strawberries ...California

Apricots ...Turkey

Raspberries ...Canada

Cocoa beans ... Amazon

Cream ...Ireland

Learning Objectives

• Define a food recall

• List three reasons why a food recall may be initiated

• How is a food recall initiated

• What are the 3 classes of recalls

Agencies Responsible for

Purchasing USDA Foods

• USDA Agricultural Marketing Service (AMS)

• USDA Farm Service Agency (FSA)

• US Department of Defense (DOD)

Food Contaminations

During production or distribution… • Accidentally (food safety issue) • Intentionally by sabotage, fraud (food defense issue) • Discovered by Regulatory or Manufacturer Food Recall Goals: Remove product from market Prevent sale or consumption

• Undeclared allergen

• Detection of hazard or disease-causing organism

• Misbranded or mislabeled product

Common causes

3 Classes of Recalls

Class 1 Reasonably likely to cause illness

E.coli (produce) Salmonella (peanut butter) Listeria (RTE)

Class 2 Remote possibility of illness

Yellow dye # 5

Class 3 Unlikely adverse effects Ingredient label not in English Defective packaging

Flow of the Recall Notice

RECALL NOTICE issued by manufacturer, supplier,

government, other)

Restaurants, Schools receives notice

On-site managers notified

Response actions by

staff

Product removal,

return

Customers notified

Product return,

disposal

Works with supplier for

proper actions

Regulatory agency

receives notice

Coordinates with industry

response

Product identification

Company Name

Brand Name

Case Markings

Establishment number (for meat, poultry, or eggs)

Product Markings

Note: UPC Code is not be adequate

Recall notice

Product description

Use-by date

Distribution area

Use-by date

LOT #

Bulk Item Challenges

Pizza that has a label that has not been positioned correctly on the box is an example of a __________ food recall.

A. Class I

B. Class II

C. Class III

D. Unidentified Class

Which of the following is not typically used to identify foods in a food recall event?

A. Lot number, UPC code, Batch #

B. Packaging characteristics

C. Recall notice

D. Food temperatures

A common cause of food recall includes

A. Undeclared allergens

B. Metal fragments in food

C. Lab identified microorganism

D. All of the above

Learning Objectives

• Locate website to sign up to receive food safety recalls

• Identify responsibilities during a food recall

• Evaluate standard operating procedures for responding to food recall

USDA Food Recall Flow Chart

AMS or FSA Purchase & Product Information

RAS/ WBSCM

USDA FNS NO

NPA Processors

Customers

SDA(Food Safety

Contact) SENS

RAs In-state

Processors Other

Entities

State Contracted Distributors

State Agency Responsibilities

• Notify Schools/ Recipient Agencies (RA) about

recalled items

• Implement standard operating procedures

• Provide disposal instructions to RAs

• Contact Processors, Distributors… instruct to ISOLATE, TRACK product in inventory

• Recall reimbursement paperwork

State-owned or Contracted

Warehouses

• Identify USDA Foods

• Document to whom USDA Foods were distributed

• Identify who received USDA Foods

• Submit inventory data to State or owner

• Conduct annual review and document compliance

RAs . Schools Responsibilities

• Have written recall procedures in place

• Assign food safety coordinator, with contact information

• Notify all sites, Schools about recalled items

• Follow instructions for Isolation or Disposal

• Avoid eating/serving recalled products, even if cooked

Product Isolation

• Segregate products until returned or declared safe

• Label clearly: “Do Not Use”

• Follow manufacturer’s instructions, FNS, USDA directives

• Alert Receiving areas

IF NECESSARY…

• Discard in a manner that prevents use or eating

• Follow guidelines by USDA, FNS, manufacturers

• Document discarded products in recordkeeping system

Disposal

Product Destruction Form

Commodity # Cases Destroyed

Contract # Destruction Method

Witnesses Print Name Signature Date Destruction Observed

Witness 1

Witness 2

Name of State Agency __________________________________________ Name of Recipient Agency_______________________________________________________

School District Contact Information:

Solid Waste Disposal

Program information at: www.epa.gov/epawaste/wyl/Stateprograms.htm

Food recalls are

A. Voluntary

B. Mandatory

C. Timely

D. Standardized

Before receiving a recall notice, RAs should

A. Implement recall procedures

B. Identify hazards in foods

C. Develop a food recall plan

D. Communicate with FSIS about commodities

An initial activity during a food recall is most likely to:

A. Identify hazards for Process 3 foods

B. Notify all schools about the recall

C. Discard all products immediately

D. Send a press release to student families

Recalls Exercise

Whose Responsibility is it?

F= Federal Agency

S= State Agency

R= Recipient Agency

P= Processor

D= Distributor

Learning objectives

• Understand methods for tracking products

• Training staff

• Conducting a mock recall

RA Tracking products

Inventory assessment in 48 hours or less Identify locations of affected product and quantity:

• Served • Remaining in-stock at schools, warehouses, distributors • Distributed to other programs • Redirected for further processing

Submit information to SDA

Critical Tracking Events

Points when product:

• Is received

• Used in production

• Is served, stored or discarded

• Shipped to another location

• Used as a leftover o Reheated

o Served or Discarded

Overall Goal

Prevent sale or consumption of Recalled foods

• Communicate with staff, others about health risks

• Work cooperatively with State/Food Regulatory agencies

• Coordinated messages to schools, public

• Document your actions

• Train staff in advance of recall event

• Demonstrate methods for isolation, destruction

• Completing forms, recordkeeping

• Evaluate gaps in your system and re-train as necessary

• Conduct a mock recall

Training staff

Conducting a Mock Recall in a School Nutrition Operation

1. Identify date and time of mock recall of produce item

2. Unannounced “TEST”

3. Have produce tracking information from vendor ready

4. Communicate produce recall to all necessary personnel

5. Provide identification information to all parties

Lot/batch #, product codes, dates, photos, etc

1. Assess affected products at each school

2. Calculate total product ( % ) accounted for at each

location (Amount in inventory, used, distributed)

3. Calculate total time to conduct the Mock recall activities

1. Identify gaps in recalls system

2. Corrective actions, revise SOPs if necessary

3. Train staff

4. Conduct another mock recall, different product, using

improved procedures, training

Conducting a Mock Recall in a School Nutrition Operation http://www.nfsmi.org/documentlibraryfiles/PDF/20130726045907.pdf

Handling complaints

• Gather information regarding complaint, product, symptoms, location, etc

• Communication

• Documentation

• Use Standard Operating Procedures for recordkeeping

Learning objectives

• List four types of records that must be kept regarding USDA Foods

• Procedures for Reimbursements

• Handling complaints

Types of Records for USDA

Foods

• Inventory

• Distribution

• Storage

• Disposal

Inventory Management System

Shows

• What food is in inventory

• When food was received

• Where food is stored

• When and where food was distributed

Reimbursement for Costs

USDA Foods Costs are limited to:

o Storage

o Transportation

o Processing

o Distribution

General Steps in Reimbursement

RAs submit original receipts & request for

reimbursement

SDA combines all requests for State &

reports data in WBSCM

SDA submits public voucher, FSA-21, &

supportive documents

USDA FNS Regional Office reviews SDA’s

claim & documentation

USDA FNS National Office reviews SDA’s

claim & documentation

USDA AMS reviews and approves

expenses

USDA AMS submits public voucher for

payment

SDA reimburses RAs (SFAs, processors,

distributors)

USDA FNS NO coordinates product replacement or

entitlement reimbursement with SDA

Thank you!

Cindy Rice, RS Eastern Food Safety cindy@easternfoodsafety.com